Effect paint

ABSTRACT

Emulsion paint composition for obtaining special textile or suede effect comprising a filler at least partly consisting of pre-pigmented spherical aliphatic polyurethane particles particles. About 3-10% of the spherical particles has a particle size between 63-90 micrometers and 25-40% of the spherical particles has a particle size between 40-63 micrometers. Before applying the paint as a semi-opaque top coat the substrate is first coated with an opaque acrylic primer of a corresponding color and subsequently dried. The top coat is applied by brush in cross way fashion to obtain a suede effect, or it can be applied by roller, while subsequently a tool is used comprising a flat side provided with stiff parallel projecting fibers such as synthetic grass fibers, which are dragged over the fresh paint layer to obtain a linen effect.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/591,037, filed Jun. 15, 2007, which is the National Phase of PCTInternational Patent Application No. PCT/EP2005/002821, having aninternational filing date of Mar. 15, 2005, which claims priority to EPApplication 0407583.4 filed Mar. 17, 2004, all of which are hereinexpressly incorporated by reference in their entireties.

The present invention relates to a method of painting a substrate, inparticular a wall, with an emulsion paint having a special visual and/ortactile effect, such as a textile, velvety or soft-feel effect. Thepresent invention also relates to a paint system to be used in such amethod, and to substrates painted using said method.

A textile or a soft-feel effect of a paint film is generally obtained byusing polyurethane particles as a filler. U.S. Pat. No. 5,498,670discloses a coating composition with spherical particles ofpolyurethane. British patent application GB-A 1 111 233 discloses avelvet-effect paint comprising spherical polyurethane particles. In EP-A0 352 804 a textile effect is obtained by using a paint with vinylchloride particles.

Larger particles, e.g. of about 90 microns or larger, generally resultin a cloudy effect, visually comparable to suede. However, the use ofsuch particles results in a relatively rough feel. Smaller particles, onthe other hand, give a soft feel but only a very limited visual textileor suede effect. Hence, a tactile effect requires a small particle size,while at the same time a visual effect is obtained only by using largerparticles.

It is the object of the invention to provide a paint compositionbalancing visual textile effects on the one hand and tactile effects onthe other. A further object of the invention is to allow the creation ofdifferent effects, such as suede, linen-like, or cloth-like effects,with the same system.

The object of the invention is achieved by means of a method of paintinga substrate by first applying an opaque coating and subsequentlyapplying a semi-opaque layer of an emulsion paint comprising sphericalpolymer particles having a particle size distribution, with 3-10% of thespherical particles having a particle size between 63-90 micrometers and25-40% of the spherical particles having a particle size between 40-63micrometers. Surprisingly, it was found that this results in acombination of a noticeable soft-feel tactile effect and a textile orsuede look as a visual effect.

In this respect, an opaque coating is a completely hiding layer ofcoating material. A semi-opaque or semi-transparent paint layer is alayer which is not completely hiding its substrate. The colour of thesubstrate is still partly visible and shines through. This way thesubstrate contributes to the final visual appearance. A semi-opaquelayer can be obtained by applying very thin layers or by using paints orlacquers with transparent pigments or with a pigment content which isnot sufficient to achieve complete hiding of the substrate with anormally applied layer of usual thickness. Usual thicknesses foremulsion paints can be as much as 150-200 micrometers.

The particles or beads should be substantially spherical. This meansthat the shape of the particles should be free of angularirregularities. The spherical particles can be made of any suitablepolymer material, such as acrylic or vinyl polymers. However,polyurethane particles are preferred, particularly aliphaticpolyurethane particles.

The specific density of the particles can for instance range between0.8-1.5 g/cm³, e.g. between 1.1-1.3 g/cm³.

Preferably, the spherical particles are pre-pigmented. The particles canbe pre-pigmented with any suitable organic or inorganic pigment, such asfor instance titanium dioxide or carbon black. The pigment content ofthe particles can for example be between 3-40%, although higher or lowercontents may also be used if so desired. Using titanium dioxide, goodresults were obtained with a pigment content of 12-15% by weight.

A particularly suitable example of a filler made of pre-pigmentedaliphatic polyurethane particles is Decol® 40, which has an averageparticle size of about 40 micrometers, a density of 1.21 g/cm³, and atitanium dioxide content of 13.5% by weight.

The emulsion paint further comprises an emulsified binder and an aqueouscarrier. Suitable binders are for example polymers obtained byhomo-polymerization or copolymerization of vinyl monomers, styrenebuilding blocks, or acrylic monomers, such as alkyl(meth)acrylates, e.g.butyl acrylate, and the like. Copolymers of butyl acrylate and styreneare preferred.

Although the emulsion paint is applied in semi-opaque dried paint films,the composition may optionally further comprise organic or inorganicpigments or further fillers. Also further paint additives can be usedsuch as pigment dispersants, emulsifiers, surfactants, thickeners,thixotropic agents, and the like.

The emulsion paint with the spherical particles can comprise furtheradditives, such as thickeners, surfactants, dispersants, coalescentaids, etc. Preferably, the paint will comprise a polyethylene wax.Further, it was found that the textile effect is improved if wood fibresare used which give the paint film a warm touch. Preferably, the woodfibres have a length between 25-35 microns.

The substrate is first coated to obtain an opaque first coating, whichcan be applied in two or more layers, although a single layer may alsobe used if so desired. The first coating can for instance be made of awater-borne emulsion paint. As in the case of the paint compositiondescribed above, this primer can for instance be an emulsion of a vinylor acrylic polymer, such as a styrene acrylic copolymer. A commerciallyavailable example of such an emulsion is HydroPliolite® available fromEliokem, at 9% volume solids in the emulsion paint.

The paint for the first opaque coating can also comprise pigments, suchas titanium dioxide, carbon black, etc., or extender pigments, such astalc, calcium carbonate or mica pigments. Preferably, the colour of theprimer should be in accordance with the colour of the paint layer withthe spherical particles.

The first coating can also comprise a thickener, such as for instance acellulose or polyurethane compound. If so desired, further paintadditives like xylan may also be used.

The first coating can be applied, e.g., by means of a brush or a roller.Medium hair rollers give the best results for this system. After theprimer has been applied in one or more layers, it is dried. Preferablyafter 12 hours or more, the semi-opaque layer of the paint comprisingthe spherical particles as described above can be applied. Also this toppaint can be applied in two or more layers, although one layer may alsobe used if so desired.

A special textile, linen-like effect can be obtained if the top paintcomprising the spherical particles as described above is applied, e.g.,by means of a medium hair roller or other suitable means, in two or morelayers, and subsequently a mattress of a fibrous material, preferably ofstiff parallel projecting fibres such as synthetic grass fibres, isdragged over the fresh paint layer.

Alternatively, the top paint can be applied by brush, preferably ofmedium size, in cross-way. This gives a cloudy, suede-like effect.

The present invention also pertains to a set of paint products includingan opaque paint and an emulsion paint with spherical particles asdefined above. Such a set may also include a tool with a mattress of afibrous material, preferably of stiff parallel projecting fibres such assynthetic grass fibres. Alternatively or additionally, such a set mayinclude a roller and/or a brush.

The invention is further illustrated by the following examples.

EXAMPLE 1

A primer was used based on an aqueous emulsion of a styrene acrylatebinder (Hydropliolite®, available from Eliokem) and comprising inorganicpigments, such as titanium dioxide, talc, calcium carbonate or micapigments.

Two layers of the primer were applied using a medium hair roller. Thelayers were dried for 12 hours and were completely hiding.

Subsequently, a paint based on an aqueous emulsion of a styrene acrylatecopolymer (11% solids) was applied as a semi-opaque layer. The paintcomprised 18% by weight of spherical aliphatic polyurethane particleswhich were pre-pigmented with titanium dioxide (13.5% by weight based onthe total weight of the polyurethane particles). These particles areavailable under the brand name Decol® 40.

Two layers of the top coat were applied by brush on the dried primerlayers in cross-way. After drying, the paint layer had a soft andsuede-like touch as well as a suede look.

EXAMPLE 2

A primer was applied as in Example 1. The same top coat was used, exceptthat this time it was applied by a medium hair roller, again in twolayers. Subsequently a tool was used comprising a blade having a flatside provided with stiff parallel synthetic fibres, similar to syntheticgrass. This fibrous flat side of the tool was dragged over the freshlyapplied top coat layers in two directions. A textile, linen-like effectwas the result.

1. A coated substrate comprising: a substrate coated with a multi-layereffect coating, said multi-layer effect coating comprising: an opaquefirst coating comprising at least one opaque layer, said first coatingbeing a water-borne emulsion of a styrene acrylic copolymer; and anemulsion paint comprising at least one semi-opaque-layer, which is overthe opaque first coating, said emulsion paint comprising sphericalpolymer particles, wherein the spherical polymer particles show aparticle size distribution in which 3-10 wt. % of the particles have aparticle size between 63-90 micrometers and 25-40 wt. % have a particlesize between 40-63 micrometers.
 2. An emulsion paint compositioncomprising: spherical polymer particles, wherein 3-10 wt. % of thespherical particles have a particle size between 63-90 micrometers and25-40 wt. % of the spherical particles have a particle size between40-63 micrometers, wherein the spherical particles are pre-pigmented. 3.The paint composition according to claim 2, wherein at least a portionof the spherical particles are polyurethane particles.
 4. The paintcomposition according to claim 2, wherein the particles have a specificdensity between 0.8-1.5 g/cm³.
 5. The paint composition according toclaim 2, wherein the paint further comprises wood fibers with a lengthbetween 25-35 microns.
 6. A set of paint products comprising: asemi-opaque emulsion paint comprising: spherical polymer particles,wherein 3-10 wt. % of the spherical particles have a particle sizebetween 63-90 micrometers and 25-40 wt. % of the spherical particleshave a particle size between 40-63 micrometers, wherein the sphericalparticles are pre-pigmented; and an opaque aqueous acrylic coatingcomposition of a corresponding color.
 7. The set of paint productsaccording to claim 6, further comprising: a tool with a flat sideprovided with a fibrous material.
 8. The paint composition according toclaim 3, wherein the particles have a specific density between 0.8-1.5g/cm³.
 9. The paint composition according to claim 3, wherein the paintfurther comprises wood fibers with a length between 25-35 microns. 10.The paint composition according to claim 4, wherein the paint furthercomprises wood fibers with a length between 25-35 microns.
 11. The setof paint products of claim 6, wherein at least a portion of thespherical particles are polyurethane particles.
 12. The set of paintproducts of claim 6, wherein the particles have a specific densitybetween 0.8-1.5 g/cm³.
 13. The set of paint products of claim 6, whereinthe paint further comprises wood fibers with a length between 25-35microns.
 14. The substrate according to claim 1, wherein the sphericalparticles are pre-pigmented.
 15. The substrate according to claim 14,wherein the pigment content of the spherical particles is between 3-40wt %.
 16. The paint composition according to claim 2, wherein thepigment content of the spherical particles is between 3-40 wt. %. 17.The paint composition according to claim 4, wherein the pigment contentof the spherical particles is between 3-40 wt. %.
 18. The set of paintproducts according to claim 6, wherein the pigment content of thespherical particles is between 3-40 wt. %.
 19. The set of paint productsaccording to claim 12, wherein the pigment content of the sphericalparticles is between 3-40 wt. % .